Collaborative Robot Cutting System and Method

Abstract

A collaborative robot cutting system for the assembly, construction, fabrication, and/or the completion of structural components for manufactured assemblies. A method of preparing work pieces and materials for further manufacturing operations employing the intuitive graphical interactive programming features of a robot cutting system user interface to enhance productivity and versatility in high mix, low volume fabrication environments with minimal operator training.

Claims

1. A highly-mobile collaborative robot cutting system for producing precise structural components from raw work material, the highly-mobile collaborative robot cutting system comprising: a highly-mobile base adapted to be to be extended in size and relocated without any significant labor and/or rigging, the highly-mobile base including a bottom or lower storage platform and an upper work surface or worktable; at least one programmable collaborative robot operatively connected to the highly-mobile base, the at least one programmable collaborative robot including a robot arm and a base operatively connected to the robot arm and adapted to mount the robot arm to the highly-mobile base; a cutting implement operatively connected to the at least one programmable collaborative robot; a power supply operatively connected to the cutting implement; a control system; and a safety system adapted to reduce an operating speed of the system in accordance with recognized safety standards in response to conditions detected by the system.

2. The highly-mobile collaborative robot cutting system of claim 1 wherein the control system includes a teach pendant and a programming or hand-guided jog button operatively connected to the control system and to the teach pendant, the teach pendant and the programming or hand-guided job button each being adapted to allow an operator to set up and program the cutting system in an intuitive and graphical manner.

3. The highly-mobile collaborative robot cutting system of claim 2 wherein the highly-mobile collaborative robot cutting system operates at a preprogrammed operating speed, the safety system comprising an operator protection safety system adapted to generate one or more non-visible safety zones or barriers surrounding the highly-mobile collaborative robot cutting system, each of the one or more non-visible safety zones or barriers being adapted to detect the presence of an object, operator, other personnel or a vehicle in at least one of the one or more safety zones or non-visible safety barriers, and to reduce the preprogramed operating speed of the collaborative robot cutting system for safety purposes in response to the detection of an object, operator, other personnel or a vehicle in at least one of the one or more safety zones or non-visible safety barriers.

4. The highly-mobile collaborative robot cutting system of claim 3 wherein the highly-mobile base includes a frame and the safety system comprises at least one LIDAR emitter/detector operatively mounted on a lower corner of the frame.

5. The highly-mobile collaborative robot cutting system of claim 4 further including an upper cantilever arm or beam operatively connected to the upper work surface or worktable, wherein the cantilever arm or beam is adapted to receive the at least one collaborative programmable robot in mounting engagement therewith.

6. The highly-mobile collaborative robot cutting system of claim 5 wherein the upper cantilever arm or beam includes a pivot connection or mounting plate adapted to operatively connect the upper cantilever arm or beam to the upper work surface or worktable and to provide rotatable positioning of the cantilever arm or beam about an axis over extended radial points above raw work material or structures, wherein the cantilever arm or beam is selectively rotatable to bring the collaborative programmable robot and cutting implement to the raw work material or structures without moving the mobile base.

7. The highly-mobile collaborative robot cutting system of claim 6 wherein the upper cantilever arm or beam further includes a pivot connection or mounting plate adapted to operatively connect the upper cantilever arm or beam to the upper work surface or worktable and to provide selective rotatable positioning of the cantilever arm or beam over extended radial points above raw work material or structures a retractable pin mechanism including a pin and actuating handle which is urged by a suitable biasing mechanism into locking engagement with one of a plurality of apertures positioned at spaced-apart radial locations on a bottom surface of the pivot connection or mounting plate.

8. The highly-mobile collaborative robot cutting system of claim 6 further including slewing ring secured to a bottom surface of the mounting plate, a servo motor operatively connected to the frame, and a pinion gear operatively connected to the servo motor and adapted to rotatably engage the slewing ring, whereby the upper cantilever arm or beam and collaborative programmable robot and cutting implement are selectively rotated to a desired radial position in response to rotational forces exerted on the slewing ring by the pinion gear.

9. A method for producing precise structural components from raw work material using a highly-mobile collaborative robot cutting system, the highly-mobile collaborative robot cutting system including at least one programmable collaborative robot having a working space and including a cutting arm member or segment and a cutting implement operatively connected thereto, a power supply, and a control system including control program software, the method comprising the steps of: a. either moving the highly-mobile collaborative robot cutting system to the raw work material to be cut or bringing the raw work material to be cut to the highly-mobile collaborative robot cutting system; b. powering on the power supply and the at least one programmable collaborative robot; c. determining if the raw work material to be cut is aligned and in position in accordance with prescribed cut specifications set forth in design drawings and specifications required by a given cutting or assembly procedure for a cut joint configuration; d. selectively engaging and disengaging a programming or hand-guided jog mechanism operatively connected to the cutting arm member or segment and the cutting implement whereby a hand-guided jogging mode is selectively engaged or disengaged at any point in a cutting process; e. moving the cutting arm member and the cutting implement to the raw work material to be cut; f. performing a clearance air move whereby the cutting arm member and the cutting implement are moved to a home position for creating a cut path; g. if the raw work material to be cut is aligned and in position in accordance with prescribed cut specification, selecting and initiating a pattern workflow subroutine robot program to establish a cut path pattern; h. selecting a cut path pattern start point or position; i. saving the cut path pattern start point or position in the pattern workflow subroutine robot program; j. performing a clearance air move whereby the cutting arm member and the cutting implement are moved to a cut path pattern end point or position; k. saving the cut path pattern end point or position in the pattern workflow subroutine robot program; l. determining the number of cut path pattern path iterations required to define a cut path pattern; m. entering the number of pattern path iterations determined in step I into the pattern workflow subroutine robot program; n. entering a starting iteration portion of the pattern workflow subroutine robot program; o. determining a set of program nodes needed to define the cut path pattern; p. entering into the pattern workflow subroutine robot program the set of program nodes and all necessary robot motions and processes required in the prescribed cut specifications to complete the cut path; q. executing the pattern workflow subroutine robot program whereby a cut path pattern is calculated; r. performing a clearance air move whereby the cutting arm member and the cutting implement are moved to a home position for creating a cut path; and s. performing a cutting operation.

10. A method for producing precise structural components from raw work material using a highly-mobile collaborative robot cutting system, the highly-mobile collaborative robot cutting system including at least one programmable collaborative robot having a working space and including a cutting arm member or segment and a cutting implement operatively connected thereto, a power supply, and a control system including control program software, the method comprising the steps of; a. either moving the highly-mobile collaborative robot cutting system to the raw work material to be cut or bringing the raw work material to be cut to the highly-mobile collaborative robot cutting system; b. powering on the power supply and the at least one programmable collaborative robot; c. determining if the raw work material to be cut is aligned and in position in accordance with prescribed cut specifications set forth in design drawings and specifications required by a given cutting or assembly procedure for a cut joint configuration; d. selectively engaging and disengaging a programming or hand-guided jog mechanism operatively connected to the cutting arm member or segment and the cutting implement whereby a hand-guided jogging mode is selectively engaged or disengaged at any point in a cutting process; e. moving the cutting arm member and the cutting implement to the raw work material to be cut; f. if the raw work material to be cut is not aligned and not in position in accordance with prescribed cut specification, selecting and initiating a search offset workflow subroutine robot program, whereby an offset cut path may be created; g. selecting and entering into the search offset workflow subroutine either a command to turn off all offsets stored in the search offset workflow subroutine robot program, or a command to turn on an offset that is saved in the search offset workflow subroutine robot program for a particular named or previously identified offset, or a command to enter a selected offset value and an offset reference feature to manually activate the search offset workflow subroutine robot program; h. executing the search offset workflow subroutine robot program whereby offsets stored in the search offset workflow are turned off or an offset is selected and an offset cut path pattern is calculated; i. performing a clearance air move whereby the cutting arm member and the cutting implement are moved to a home position for creating an offset cut path; and j. performing a cutting operation.

11. The method of claim 1 wherein the step of performing a cutting operation includes the steps of: a. selectively engaging the hand-guided jogging mode and performing a clearance move whereby a home position is created; b. selecting and initiating a search part subroutine robot program whereby a one-dimensional linear search adapted to identify a program offset or displacement that shifts a program in response to detected positional, rotational or distortional inconsistencies in the raw work material or unrepeatable configurations of a part to be processed; c. moving the cutting arm member and the cutting implement in hand-guided jogging mode to a selected point that is in contact with the raw work material or part; d. saving the selected point in the search part subroutine robot program as a search start point; e. selecting an offset name for storage and retrieval of a resultant offset or displacement value from the search part subroutine robot program; f. entering a search distance and a reference feature upon which an offset or displacement value may be calculated; g. initiating a search; h. moving the cutting arm member and the cutting implement in a programmed search direction until the cutting implement contacts the raw work material or the part; whereby a force feedback signal is generated by the control unit in response to the cutting implement contacting the raw work material or the part and a new contact point is generated; i. halting the motion of the cutting arm member and the cutting implement in response to the force feedback signal; j. comparing the new contact point to the reference feature; k. calculating an offset or displacement value; and l. storing the offset or displacement value in the offset name in the search part subroutine robot program; m. generating a cut path.

12. The method of claim 11 further including the step of overriding the search distance entered at step f; entering a different search distance, and repeating steps g though m.

13. The method of claim 11 further including performing steps d through f of claim 10 after performing step I.

14. A method for producing precise structural components from raw work material using a highly-mobile collaborative robot cutting system, the highly-mobile collaborative robot cutting system including at least one programmable collaborative robot having a working space and including a cutting arm member or segment and a cutting implement operatively connected thereto, a power supply, and a control system including control program software, the method comprising the steps of: a. either moving the highly-mobile collaborative robot cutting system to the raw work material to be cut or bringing the raw work material to be cut to the highly-mobile collaborative robot cutting system; b. powering on the power supply and the at least one programmable collaborative robot; c. determining if the raw work material to be cut is aligned and in position in accordance with prescribed cut specifications set forth in design drawings and specifications required by a given cutting or assembly procedure for a cut joint configuration; d. selectively engaging and disengaging a programming or hand-guided jog mechanism operatively connected to the cutting arm member or segment and the cutting implement whereby a hand-guided jogging mode is selectively engaged or disengaged at any point in a cutting process; e. moving the cutting arm member and the cutting implement to the raw work material to be cut; f. performing a clearance air move whereby the cutting arm member and the cutting implement are moved manually to a waypoint for initiating the creation of a cut path; g. selecting and initiating a cut path template workflow subroutine robot program adapted to generate a cut path template; h. manually selecting a cut start waypoint; i. manually positioning the cutting arm member and the cutting implement at a selected approach point and entering the approach point into the cut path template workflow subroutine robot program; j. manually positioning the cutting arm member and cutting implement at a cut start waypoint and entering the cut start waypoint into the cut path template workflow subroutine robot program; k. selecting the cut process data by manually tracing out the cut path by creating one or more cut thought way points, at least one cut end way point, and a depart point in hand-guided jogging mode and entering all of the one or more cut thought way points, the at least one cut end way point, and the depart point into the cut path template workflow subroutine robot program, thereby generating a cut path template; l. returning the cutting arm member and the cutting implement to the cut start waypoint; m. selecting a cutting process to be executed by the cutting arm member and the cutting implement as the cutting arm member and the cutting implement move along the cut path from the cut start point through the one or more cut through way points, and the at least one cut end point; and n. executing the selected cutting process and the cut path template whereby a cut path is generated.

15. A method for producing precise structural components from raw work material using a highly-mobile collaborative robot cutting system, the highly-mobile collaborative robot cutting system including at least one programmable collaborative robot having a working space and including a cutting arm member or segment and a cutting implement operatively connected thereto, a power supply, and a control system including control program software, the method comprising the steps of: a. either moving the highly-mobile collaborative robot cutting system to the raw work material to be cut or bringing the raw work material to be cut to the highly-mobile collaborative robot cutting system; b. powering on the power supply and the at least one programmable collaborative robot; C. determining if the raw work material to be cut is aligned and in position in accordance with prescribed cut specifications set forth in design drawings and specifications required by a given cutting or assembly procedure for a cut joint configuration; d. selectively engaging and disengaging a programming or hand-guided jog mechanism operatively connected to the cutting arm member or segment and the cutting implement whereby a hand-guided jogging mode is selectively engaged or disengaged at any point in a cutting process; e. moving the cutting arm member and the cutting implement to the raw work material to be cut; f. performing a clearance air move whereby the cutting arm member and the cutting implement are moved manually to a waypoint for initiating the creation of a cut path; g. selecting and initiating a cut path template workflow subroutine robot program adapted to generate a cut path template; h. selecting an automatically positioned approach point in the cut path template workflow subroutine robot program; i. manually positioning the cutting arm member and cutting implement at a cut start waypoint and entering the cut start waypoint into the cut path template workflow subroutine robot program; j. selecting the cut process data and entering it into the cut path template workflow subroutine robot program; k. manually positioning the cutting arm member and cutting implement at a cut end waypoint and entering the cut end waypoint into the cut path template workflow subroutine robot program; l. selecting an automatic depart point; and m. initiating execution of the cut path template.

16. A method for producing precise structural components from raw work material using a highly-mobile collaborative robot cutting system, the highly-mobile collaborative robot cutting system including at least one programmable collaborative robot having a working space and including a cutting arm member or segment and a cutting implement operatively connected thereto, a power supply, and a control system including control program software, the method comprising the steps of: a. either moving the highly-mobile collaborative robot cutting system to the raw work material to be cut or bringing the raw work material to be cut to the highly-mobile collaborative robot cutting system; b. powering on the power supply and the at least one programmable collaborative robot; c. determining if the raw work material to be cut is aligned and in position in accordance with prescribed cut specifications set forth in design drawings and specifications required by a given cutting or assembly procedure for a cut joint configuration; d. selectively engaging and disengaging a programming or hand-guided jog mechanism operatively connected to the cutting arm member or segment and the cutting implement whereby a hand-guided jogging mode is selectively engaged or disengaged at any point in a cutting process; e. moving the cutting arm member and the cutting implement to the raw work material to be cut; f. performing a clearance air move whereby the cutting arm member and the cutting implement are moved manually to a waypoint for initiating the creation of a cut path; g. selecting and initiating a cut shape template workflow subroutine robot program in the control program software adapted to generate a cut shape template; h. selecting a cut shape type and choosing a shape template from a shape library stored in the control program software; i. selecting the shape positions and shape dimensions required to define a cut shape; j. creating the cut shape defined in step I; k. manually selecting an approach waypoint and entering it into the cut shape template workflow subroutine robot program; l. manually positioning the cutting arm member and cutting implement at the approach waypoint and entering the approach waypoint into the cut shape template workflow subroutine robot program; m. selecting the cut process data and entering it into the cut shape template workflow subroutine robot program; n. manually selecting a cut depart waypoint and entering it into the cut shape template workflow subroutine robot program; o. manually positioning the cutting arm member and cutting implement at the cut depart waypoint; p. executing the cut shape template.

17. The method of claim 16 wherein step I, positioning the cutting arm member and cutting implement at the approach waypoint and entering the approach waypoint into the cut shape template workflow subroutine robot program, is performed automatically by the control system and control program software.

18. The method of claim 17 wherein step n, selecting a cut depart waypoint and entering it into the cut shape template workflow subroutine robot program, is performed automatically by the control system and control program software.

19. The method of claim 16 wherein step n, selecting a cut depart waypoint and entering it into the cut shape template workflow subroutine robot program, is performed automatically by the control system and control program software.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Referring now to the attached drawings which form a part of this original disclosure:

[0036] FIG. 1 is a right top perspective view of the elements of a collaborative robot cutting system having a mobile base in accordance with an embodiment of the present invention;

[0037] FIG. 2 is a rear top perspective view of the collaborative robot cutting system of FIG. 1 in accordance with an embodiment of the present invention;

[0038] FIG. 3 is a rear perspective view of the elements of the collaborative robot cutting system shown in FIGS. 1 and 2 illustrating the components thereof in greater detail;

[0039] FIG. 4 is an oblique top front perspective view of a collaborative robot cutting system including a selectively positionable extended support member operatively rotatably connected to an extended upper surface thereof having a mobile base including a corner-mounted operator protection safety system in accordance with an embodiment;

[0040] FIG. 5 is an enlarged perspective view of an element of the corner-mounted operator protection safety system of the collaborative robot cutting system of FIG. 4;

[0041] FIG. 6 is a top plan view of the collaborative robot cutting system of FIG. 4 illustrating the safety sensing areas of the corner-mounted operator protection safety system;

[0042] FIG. 6A is a flow diagram of the operation of the safety sensing areas of the corner-mounted operator protection safety system of the collaborative robot cutting system of FIGS. 4-6;

[0043] FIG. 6B is a flow diagram of the operation of the safety sensing areas of the corner-mounted operator protection safety system of the collaborative robot cutting system when used in conjunction with the motorized rotation system of FIGS. 9-10;

[0044] FIG. 7 is a left side perspective view of the collaborative robot cutting system shown in FIG. 4;

[0045] FIG. 8 is a left bottom perspective view of the collaborative robot cutting system of FIGS. 4 and 7;

[0046] FIG. 9 is a lower left side perspective view a collaborative robot cutting system having a motorized rotation system adapted to rotatably position a selectively positionable extended support member rotatably operatively connected to an upper surface thereof in accordance with an embodiment;

[0047] FIG. 10 is a bottom front perspective view of the collaborative robot cutting system of FIG. 9 showing the motorized rotation system enlarged to better illustrate the elements thereof;

[0048] FIG. 11 is a top perspective view of the collaborative robot cutting system of the present invention performing a cutting operation on a side panel of a channel member;

[0049] FIG. 12 is a top perspective view of a beveled edge of a steel plate cut by the collaborative robot cutting system of the present invention;

[0050] FIG. 13 is a top perspective view of the collaborative robot cutting system of the present invention cutting the beveled edge of FIG. 12;

[0051] FIG. 14 is a top perspective view of collaborative robot cutting system of the present invention performing a cutting operation on an edge of a channel member;

[0052] FIG. 15 is a top perspective view of collaborative robot cutting system of the present invention performing a cutting operation on an edge of an angle iron;

[0053] FIG. 16 is a side elevation view of a collaborative robot arm positioned for attachment to a magnetic locking base in accordance with an embodiment;

[0054] FIG. 17 is a side elevation view of the robot arm and mechanical locking base of FIG. 16 illustrating the robot arm mounted on the magnetic mounting base;

[0055] FIG. 18 is a perspective view of the robot arm and magnetic mounting base of the embodiment of FIG. 17 enlarged to more clearly illustrate the elements thereof;

[0056] FIG. 19 is a flow diagram depicting the process steps of an exemplary cutting job cycle;

[0057] FIG. 20-A is a perspective view of a collaborative robot arm in accordance with an embodiment;

[0058] FIG. 20-B is a flow diagram illustrating the process workflow steps of the hand guided jogging movement of the robot arm;

[0059] FIG. 21 is a flow diagram of an AirMove workflow;

[0060] FIG. 22 is a pictorial representation or screen shot of an AirMove workflow defining a curved cut path as displayed on an input screen of a teach pendant;

[0061] FIG. 23 is a pictorial representation or screen shot of an AirMove workflow defining a linear cut path as displayed on an input screen of a teach pendant;

[0062] FIG. 24 is a flow diagram of a Pattern workflow;

[0063] FIG. 25 is a pictorial representation or screen shot of a Pattern Tool defining a non-linear cut path to be repeated as displayed on an input screen of a teach pendant;

[0064] FIG. 26 is a flow diagram of a SearchOffset workflow;

[0065] FIG. 27 is a pictorial representation or screen shot of a SearchOffset workflow defining offset values to turn on as displayed on an input screen of a teach pendant;

[0066] FIG. 28 is a pictorial representation or screen shot of a SearchOffset workflow defining offset values to turn off as displayed on an input screen of a teach pendant;

[0067] FIG. 29 is a pictorial representation or screen shot of a SearchOffset workflow defining specific offset values to turn on as displayed on an input screen of a teach pendant;

[0068] FIG. 30 is a flow diagram of a SearchPart workflow;

[0069] FIG. 31 is a pictorial representation or screen shot of a Search Part workflow illustrating values identified during a search as displayed on an input screen of a teach pendant;

[0070] FIG. 32A is a flow diagram of a Cut Template Custom workflow;

[0071] FIG. 32B is a continuation of the flow diagram depicted in FIG. 32A;

[0072] FIG. 33 is a pictorial representation or screen shot of a Cut Template Custom workflow illustrating a cut approach point and distance;

[0073] FIG. 34 is a pictorial representation or screen shot of a Cut Template Custom workflow illustrating a cut start point;

[0074] FIG. 35 is a pictorial representation or screen shot of a Cut Template Custom workflow illustrating cut process data;

[0075] FIG. 36 is a pictorial representation or screen shot of a Cut Template Custom workflow illustrating a cut end point;

[0076] FIG. 37 is a pictorial representation or screen shot of a Cut Template Custom workflow illustrating a cut depart point and distance;

[0077] FIG. 38A is a flow diagram of a Cut Template Shape workflow;

[0078] FIG. 38B is a continuation of the flow diagram depicted in FIG. 38A;

[0079] FIG. 39 is a pictorial representation or screen shot of a Cut Template Shape workflow illustrating the shape selection;

[0080] FIG. 40 is a pictorial representation or screen shot of a Cut Template Shape workflow illustrating the shape parameter input;

[0081] FIG. 41 is a pictorial representation or screen shot of a Cut Template Shape workflow illustrating a cut approach point and distance;

[0082] FIG. 42 is a pictorial representation or screen shot of a Cut Template Shape workflow illustrating cut process data;

[0083] FIG. 43 is a pictorial representation or screen shot of a Cut Template Shape workflow illustrating a cut depart point and distance;

[0084] FIG. 44 is a pictorial representation or screen shot of a CutThru/CutEnd Template illustrating a circular cut thru move;

[0085] FIG. 45 is a pictorial representation or screen shot of a CutThru/CutEnd Template illustrating a circular cut end move; and

[0086] FIG. 46 is a pictorial representation or screen shot of a CutThru/CutEnd Template illustrating a linear cut having at least two segments and a waypoint.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0087] Selected embodiments of the present invention will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments of the present invention are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claim and its equivalents.

Overview of System for Cutting

[0088] First, the operator/programmer either brings the work materials to be cut to the collaborative robot or, alternatively, brings the robot to the work material. If the collaborative robot is taken to the work material, the cutting system, by way of example and not of limitation a plasma cutting machine, is plugged into available single phase or three phase wall power, and the collaborative robot is plugged into an available 120V outlet. Once both devices are powered on, the operator/programmer starts positioning the collaborative robot for the work material to be plasma cut. The first positions that the operator/programmer will teach are clearance AirMove's to position the robot in preparation for the cutting. The primary means of moving the collaborative robot and the cutting torch to the work material is via the programming button that releases the robot into a hand-guided jogging fashion where the operator/programming can push/pull the robot into the appropriate position. When the operator/programmer starts positioning the collaborative robot, he/she ensures they have a cutting or assembly print that will be used to identify shape and location of the cutting to be performed on the work material. If the desired work material will vary in positional location or the collaborative robot is moved to the work material, tactile searching/sensing is needed to ensure the trajectory of the collaborative robot is properly placed in the joint considering this variation. If one of these conditions exists, the operator/programmer plans out the searching scheme and where the offsets will be needed for the cutting operation that will be performed on the work material. If searches are needed, the operator/programmer zeros out these searches treating this part as the baseline part for correlation of searches to all subsequent cut templates. Once the operator/programmer has added in searches and appropriate offset activation, the appropriate cut templates can be added. Each of these cuts may be a shape cut such as a slot, square, rectangle, circle, etc. or a free multisegmented path cut based on the cutting or assembly print. These various types of cuts will be added using the build in programming tools for each particular type of cut that is added.

[0089] The cutting system includes a shape library that enables the operator/programmer to precisely teach one of the stored shape cuts with imputed parameters such as width, length, and radius. Once the cuts have been added to the program, the operator/programmer chooses the required cutting process. If the appropriate cutting process is not in the system, the process will be developed using an existing set of data that is adjusted by slowing down or speeding up while adjusting amperage based on the thickness. This process of adding searches, if needed, and cut templates is repeated for all necessary cuts across the work material to be cut. Between each of these sets of searches and cut templates, any necessary AirMove's will be added for clearance or conduit bundle cable management. Once all necessary moves have been added to the collaborative robot, the operator/programmer saves the program in the robot for future repetitive use. In either case where the work material was brought to the collaborative robot or the robot was taken to the work material, the position of the robot relative to the work material must be recorded or outlined on the floor.

[0090] Referring initially to FIGS. 1 and 2, an exemplary collaborative robot cutting system, referred to hereinafter as the cutting system for purposes of brevity, is shown generally at the numeral 10. The cutting system includes a mobile worktable, base or cart 15, as the terms may be used interchangeably herein, having a frame 17, a plurality of supporting legs 20, each including a levelling device or foot 21 attached thereto, a storage area or platform 24 having wheels or casters 25 mounted to a bottom surface 27 thereof (FIG. 3), and a gridded upper work surface or table 29. The upper work surface includes a plurality of apertures 30 formed therein, each of the apertures being adapted to releasably receive a clamp or other securement device for holding a workpiece, fixture or assembly in a fixed position during the performance of a cutting sequence using the cutting system.

[0091] The cutting system 10 further includes a collaborative robot system 50 (known in the art as a cobot), such as a Universal Robots UR10e collaborative industrial robot. However, it is to be understood that collaborative robot systems either specifically designed and built for individual applications or other generally commercially available collaborative robot systems may also be used without departing from the scope of the present invention. The collaborative robot system comprises a robot arm 55 operatively connected to a base 57, which, in turn, is mounted on an electrically isolating pad 60 secured by suitable fasteners 62 to the upper work surface 29. As best seen in FIG. 2, the robot arm includes a plurality of arm segments 65a-65f sequentially pivotally and/or rotatably interconnected to one another and structured and arranged to have a reach length or distance which depends upon the size of the robot arm selected for use in the system 50 and the lengths of its individual segments. A safety feature (not shown) is built into the control system and the robot arm and is structured and arranged to interrupt movement of the arm, should it come in contact with the operator or another object. A cutting implement or torch 70 is secured via an attachment 72 to a distal end 75 of the robot arm, the implement being universally positionable and translatable along a preselected cut path in response to instructions from a robot controller 78, teach pendant 80 and application programming interface (API) display 85. In the embodiment of FIGS. 1-2, by way of example and not of limitation, the implement 70 is depicted in the form of a cutting torch and cutting nozzle 71 representative of the type used in plasma cutting processes; however, it is to be understood that the system of the present invention may be used with any cutting process without departing from the scope of the present invention. The members of the collaborative robot system 50 are covered by a protective material or shield wrap 90 to protect the elements thereof from spatter generated by cutting operations.

[0092] A programming or hand-guided jog button 92 is secured to the attachment 72 and is operatively connected to the robot controller 78 and teach pendant 80 and, as will be described in greater detail below, is adapted to allow an operator to set up and program the cutting system in an intuitive and graphical manner. Compressed air and cutting consumables such as cutting gas are delivered from a central gas supply system or from individual gas cylinders along with electrical power cables via a torch bundle 93 supported by support arm or bracket 94 secured to the robot arm to the cutting nozzle 71, as is known in the art. Power is provided to the cutting implement via power supply 95, and the power supply, robot controller, teach pendant, and any ancillary power tools an operator may need all may be operatively connected to single phase power, for example, 120V power for the collaborative robot system and 240V power for the power supply. Optionally, the power supply may be connected to 208V, 480V or 575V three phase power.

[0093] The availability of conventional shop power combined with the portability of the worktable contribute to the overall flexibility and adaptability of the cutting system. It can be brought to the location of the work material and set up anywhere in a shop or in the field quickly with little lead time. The cutting system 10 in the embodiment of FIGS. 1-3 mounted on the worktable occupies a small area having a full system footprint of approximately three (3) feet wide and six (6) feet deep, and does not require a large investment in utilities, dedicated factory space, safety guards and materials handling equipment. The cutting system of the present invention is particularly adaptable for high mix, low production small or medium-sized piece parts such as brackets, tubes, handles, and the like, as shown in FIGS. 11-15.

[0094] Referring now to FIGS. 4-8, the elements of a collaborative robot cutting system 100 having a selectively positionable extended support member 110 is illustrated in accordance with an embodiment. The extended support member is in the form of a selectively positionable cantilever beam 110 having a proximal end 112 and a distal end 114 rotatably operatively connected to an upper work surface or table 129. Similar in construction and operation to the embodiment of FIGS. 1-3, cutting system 100 includes an extended worktable or mobile cart 115 having an extended size of approximately six (6) feet wide and six (8) feet deep. The worktable or mobile cart includes a frame 117, a plurality of supporting legs 120, each including a levelling device or foot 121 attached thereto, a storage area or platform 124 having wheels or casters 125 mounted to a bottom surface 127 thereof.

[0095] The collaborative robot cutting system 100 is designed to process larger work materials and parts by augmenting the reach of the cobot 50 by mounting it on the distal end 114 of the cantilever beam 110. The augmented reach of the system is further enhanced via a pivot connection or mount shown generally at 130 which is adapted to permit selective rotatable positioning of the cantilever beam and cobot cutting system over extended radial points above large work material or structures. The pivot connection includes a mounting plate 131 secured to the distal end of the cantilever beam and rotatable secured to a bearing shaft or post 132 operatively connected to the upper work surface or table 129. Cable guide 135 (FIG. 8) is secured to a mounting bracket 137 operatively connected to a bottom surface 140 of the work surface or table and adapted to support the torch bundle 93 and electrical power cables as the cantilever beam rotates about pivot connection 130. To achieve consistency and repeatability in positioning the cobot, a retractable pin mechanism 145 including a pin 147 and actuating handle 149 which is urged by a suitable biasing mechanism, by way of example and not of limitation a spring or a hydraulically actuated piston, into releasable locking engagement with a preselected one of a plurality of apertures 150 positioned at spaced-apart radial locations on a bottom surface 155 of the mounting plate 131 (FIGS. 9 and 10).

[0096] Referring now to FIGS. 9 and 10, a collaborative robot cutting system 200 having a selectively positionable extended support member 210 is illustrated in accordance with another embodiment of the present invention. Of similar configuration to that of the embodiment 100 of FIGS. 4-8, cutting system 200 includes a worktable or mobile cart 215. The worktable or mobile cart includes a frame 217, a plurality of supporting legs 220, each including a levelling device or foot 221 attached thereto, a storage area or platform 224 having wheels or casters 225 mounted to a bottom surface 227 thereof, and an upper work surface or table 229. In contrast to the selective rotatable positioning of the cantilever beam 110 in the embodiment of FIGS. 4-8 which is performed manually by an operator, the cantilever beam in the embodiment of FIGS. 9 and 10 is selectively positioned by a slewing ring-pinion gear mechanism 230 activated by a servo motor 232 mounted on the frame 217. A pinion gear 235 is operatively connected to the servo motor and adapted to rotatably engage a slewing ring 237 secured to the bottom surface 155 of the mounting plate 131. The servo motor may be selectively activated to rotate in either direction, thus rotatably urging the cantilever beam and cobot cutting system to a desired radial position in response to rotational forces exerted on the slewing ring by the pinion gear.

[0097] In the operation of the collaborative robot cutting system 100, an operator/programmer would select the pin location that centers the cobot over the desired operating space. The operator then programs all necessary cut paths within the selected pin location and titles the program accordingly, by way of example, cutting program at 45 degrees, etc. To prevent errors, the system could optionally have proximity sensors at positions designated by various degrees to tell the system which pin location it is positioned at and to ensure that the cobot executes the correct program for that position. The operator would then move the cantilever beam to another pin location and repeat the procedure above for another degree increment such as 90 degrees. Between each of the steps in the program, a message box could be used to tell the operator which position to move the cantilever beam to before proceeding to the next cutting operation at a new pin location.

[0098] In the operation of the collaborative robot cutting system 200 using the slewing ring-pinion gear mechanism 230, the pivot axis is the seventh axis that would be saved with each programmed cobot position. This ensures that the pivot axis rotates to the selected position when the cobot is moving to a global XYZ position. In this case, the programmer would select the degree angle to which the pivot axis is to be rotated prior to programming any cobot positions. Once the pivot axis is in the correct position, the programmer adds all necessary cut paths associated with the pivot axis position and saves them for execution at the specific pivot axis position. Upon completion of the cuts to be made at the specified pivot axis position, the operator repeats the process for another pivot axis position.

[0099] To protect an operator using the slewing ring-pinion gear mechanism 230 to position the cantilever beam and cutting system 200, safety scanners would be used to protect the operating space of the combination of the cobot and the pivot axis. When the system is in programming mode or manual mode, the safety scanners would not be functioning. When the system is in operating mode, the scanners would be active and would stop the system if someone enters the safeguarded space that is protected by the sensors. As will be described in greater detail below, the system further includes a corner-mounted operator protection safety system 260 (FIGS. 4-5) which detects the presence of an operator, other personnel or a vehicle such as a forklift in preselected safety zones or non-visible safety barriers

[0100] Referring now to FIG. 5, the elements of the corner-mounted operator protection safety system 260, referred to hereinafter as the LIDAR safety system or alternatively, the safety system, as appropriate in the context is shown in greater detail. LIDAR is an acronym for light detection and ranging or, alternatively, laser imaging, detection, and ranging, a system which uses ultraviolet (UV), visible or near infrared (NIR) light to detect objects and to determine ranges or distances from the emitter/detector to the object. The LIDAR system of the corner-mounted operator protection safety system 260 of the collaborative robot cutting system of the instant invention is used to detect the presence of an operator, other personnel or a vehicle such as a forklift in preselected safety zones or non-visible safety barriers 263, 265 illustrated in FIG. 6 surrounding the collaborative robot cutting system 200. These safety zones or barriers are shown in FIG. 6 and are generated by the LIDAR scan projected out by the system. When and object is detected in one of the zones, the operating speed of the robot system is reduced for safety purposes or the robot system is stopped if used with the motorized rotation system. Coupled with the built-in safety system of the robot arm, which stops its movement when the arm contacts an object, the system possesses dual chain safety feature redundancy. This feature also enhances production rates, inasmuch as the system may be operated confidently at higher speeds under normal conditions knowing that if an unsafe condition is detected, the system will respond proactively to protect the operator and other personnel in the area.

[0101] As illustrated in FIG. 5, the LIDAR safety system is adjustably and rotatably secured to the bottom surface 127 of the mobile cart 115 by brackets 267 and 269. The operating and control components of the system are contained within cylindrical housing 270 and in projector housing 272 which are adjustably positionable to control the radii 275, 280 and the corresponding circumference ranges 285, 290 of the safety zones 263, 265 generated by the LIDAR safety system scan, respectively.

[0102] The operational flow chart of the LIDAR safety system is presented in FIG. 6A. When the collaborative robot cutting system has been programmed and set up for a particular job and has completed the programmed cutting tasks or if the system is sitting idle, if an operator walks up to the system, he or she will enter one or both of the safety zones 263, 265 thereby breaking the non-visible safety barrier. In response, the robot speed mode is adjusted downward at step B, and the operating speed is reduced to a preselected safe level but is not shut down. At step C, the operator, who is now within the safety zones, may safely and confidently perform programming operations, unload work materials already cut, load and adjust new work materials for the next cutting cycle, and perform other tasks associated with operating the cobot 50. The operator then selects the program to execute with the new work materials and presses the air button on the robot either via the pendant or operator panel. The program starts and the operator walks out of the non-visible safety barrier. The robot then speeds up to the allowable maximum speed while continuing the current program it is executing. At step D, the LIDAR safety system continually checks to determine if the robot program is running and if the scan is interrupted at step E, which would indicate that the operator has reentered the safety zones. If the scanner indicates that the operator is still in the safety zones, the robot operating speed is maintained at a reduced speed level, step F. If the scanner is uninterrupted, which indicates that the operator has completed his or her tasks within the safety zone and moved out of them, the system returns the robot operating speed to the preselected full operating speed for the task being performed at step G. The system continuously checks for any breakage of the non-visible safety barrier or obstacle that would slow the robot operating speed down, step E, or completion of the program at steps H and I, thereby providing closed loop feedback to the control system of the status of the robot program. If the system detects that the program is finished at step J, the operation is complete and the operator may approach the mobile cart 215 to perform a new setup, reprogram the robot or to execute other required tasks. The main usefulness for the safety system is speeding up all the non-process moves to reduce the cycle time of the system to the most efficient cycle time possible with any given job.

[0103] The operational flow chart of the LIDAR safety system when used in conjunction with the motorized rotation system is presented in FIG. 6B. When the collaborative robot cutting system has been programmed and set up for a particular job and is now running the program, step A, the operator walks up to the system entering one or both of the safety zones 263, 265 thereby breaking the non-visible safety barrier, step B. At step C, the safety system checks if the robot is in programming mode and if system is not in programming mode, the robot stops due to a safety stop, step D. To clear this safety fault, step E, the operator walk out of the safety zones 263, 265 and the LIDAR safety system fault is cleared, step F. Once the fault is cleared by exiting the safety zones, the operator restarts the program from the teach pendant 80. If the system was in programming mode, step C, the safety stop is ignored, step H, and robot continues the program, Step I. The main usefulness for the safety system is protecting the operator from the pinch points that are created between the extended support member 110 and mobile cart 115 as illustrated in FIG. 4.

[0104] Referring now to FIGS. 16, 17, and 16, a collaborative robot cutting system 50 is shown mounted to a quick release cam lock 460; such a MGW GRIP connector or a SWS GRIP Connector manufactured by GRIP GmbH, Dortmund, Germany; as well as a magnetic base 450 such a Magswitch UR 10 isolated cobot magnetic base manufactured by Magswitch Technology, Lafayette, Colorado. The magnetic base is releasably positioned at any location suitable for the work material to be cut either on the material or on the worktable adjacent to the material, and the collaborative robot cutting system 50 is positioned thereon. The magnetic base is releasably secured via activation lever 455 which moves magnets positioned in the base close to the material to be cut, thereby creating sufficient securing forces to maintain the collaborative robot cutting system in position. The base 57 of the collaborative robot cutting system 50 is adapted to fit over a cylindrical cam locking attachment member located on a top surface 451 of the magnetic base, and the collaborative robot cutting system 50 is releasably secured thereto via activation lever 58 which moves a cam lock positioned in the base from the released position into the locked position, thereby creating sufficient securing forces to maintain the collaborative robot cutting system in position. After cutting operations have been completed, the collaborative robot cutting system 50 may be released by moving the activation lever in the opposite direction, and the collaborative robot cutting system may be repositioned at another selected location on the worktable.

[0105] The cutting systems 100 and 200 both include a collaborative robot system or cobot 50 as shown in FIGS. 1-3 and described in detail above. For purposes of clarity and simplicity, the same robot system component numeric identifiers are also used in the embodiment of FIGS. 4-7. Collaborative robot systems either specifically designed and built for individual applications or other generally commercially available collaborative robot systems may also be used in the embodiments of FIGS. 4-7 without departing from the scope of the present invention.

[0106] The embodiments depicted in FIGS. 1-10 further illustrate the flexibility and adaptability of the cutting system 10 of the present invention, inasmuch as the portability of the system coupled with the reach distance or length of the robot arm allows the system to be used to perform cutting operations on assemblies or structures that may be difficult or uneconomical to move or, alternatively which may be permanently fixed to larger structures. For example, storage vessels, petrochemical processing equipment, or large open pit mining shovels may experience structural failures, weld cracking or other problems which may be require field repair by cutting and replacement welding. The entire cutting system including all of the individual components, namely, the worktable, the cutting power supply, robot controller, teach pendant, and cutting gas supply may be positioned as a unit on an elevated platform, scaffolding, a cherry picker (boom lift) or a scissor lift for performing cutting operations in relatively inaccessible locations. Alternatively, the individual components may be positioned separately independently of the worktable, and the mechanically secured base 60 may be replaced by a magnetic base affixed to a sidewall, roof or ceiling portion of a steel structure to perform out of position cutting operations in both indoor manufacturing and field service maintenance applications.

[0107] In operation, by way of example and not of limitation, the collaborative robot cutting system 10 of the present invention may be used to cut intricate shapes and patterns into work materials such as an advertising logo 350 in a box beam member 352 as shown in FIG. 11. FIG. 12 depicts a beveled edge 360 prepared in anticipation of welding the substrate member 365 to a cooperating adjacent member in a welded assembly. FIG. 13 depicts a beveled edge 370 being cut in a steel plate 375, and FIG. 14 illustrates the preparation of edges 377, 378 in the side members 380 of a square tube assembly 384. Finally, FIG. 15 shows the final segment of a cutting operation performed on an edge 390 of an angle iron 395 which commenced at the right corner 397 of the workpiece and will finish at the left corner 399.

[0108] Referring now to FIG. 19, a flow diagram or flow chart presents the process steps of an exemplary cutting job cycle. The novel intuitive and graphical programming features and operational methodology for using the cutting system are described in FIGS. 20-46 via exemplary screen shots of processing steps and commands as they appear in the application programming interface (API) display 85 of the teach pendant 80 and in supplemental flow diagrams associated therewith. These figures are cross referenced where applicable to the flow chart process steps in the description following. Analogous to setting up a route via waypoints between a start point and a destination using a GPS system, the teach pendant is organized in such a way as to permit an operator or programmer, which designations are used interchangeably herein, to program a job without having an extensive educational background or computer programming or coding training or experience.

[0109] First, the operator brings the work materials to be cut to the collaborative robot such as where the system 200 of FIG. 9 is advantageously employed for cutting large assemblies. Alternatively, the operator brings the collaborative robot to the work material, as for example, in the situation where cutting must be performed in the field and powers on the cutting power supply and the collaborative robot. The work material aligned in accordance with the prescribed cut specifications set forth in the associated design drawings and specifications and may be tacked, held in a fixture, or otherwise secured in position. At this point and at any point in the setup and cutting process, the operator may select the hand-guided jogging mode as shown in FIGS. 20A and 20B by depressing the programming or hand-guided jog button 92 on the handle of the cutting torch bracket 72. This mode permits free movement and positioning of the robot arm 55 and the torch 70 by the operator. The operator may conveniently engage and disengage the hand-guided jogging mode as needed at any time during the performance of a cut setup and execution procedure. Once the work materials and the robot arm are located relative to one another, the operator may commence the program setup by using the programming button 92 in conjunction with the teach pendant 80 to create a cutting path.

[0110] The operator performs a clearance move of the robot arm 55, designated as an AirMove Workflow in step A, FIG. 19 and creates a home position shown as point A on a curved AirMove screenshot 500 and as point A on a linear AirMove screenshot 505 in FIGS. 22 and 23, respectively, to ensure that the robot arm can start from a home or approach position of a cut path indicated generally at 501 and 503 respectively in each of the pictorial presentations. FIG. 21 presents alternate flow diagrams based upon the operator's selection at step B of AirMoveJ for a curved or circular cut path or choice C of AirMoveL for a linear cut path, choice C. An AirMove is a simple move that positions the arm in the working space of the robot. It can be done via a free joint motion (AirMoveJ) where the robot calculates the most optimal movement or in a linear fashion (AirMoveL) where the robot moves directly to a waypoint in a straight line. In either scenario, the operator positions selected waypoints, also referred to herein as airpoints, by moving the robot arm and torch in the hand-guided jogging mode (either step D or step E in FIG. 21) which the robot saves at step F.

[0111] Depending upon the configuration of the cut path, the operator may select a Pattern Workflow subroutine at FIG. 19, step B to establish a cut pattern such as pattern 510 of a circular cut path illustrated in the image of a Pattern screen shot 517 in FIG. 25. The steps of a Pattern Workflow 515 are shown in a flow chart presented in FIG. 24. The operator programs a Pattern Start position (point A in FIG. 25) in hand-guided jogging mode, FIG. 24, step A and saves it in the robot program, step B. The operator then enters hand-guided jogging mode and establishes a Pattern End position (point B in FIG. 25) in step C and saves it, step D. The Pattern Workflow subroutine allows the operator to program a repeatable part that is in a straight line for a number of iterations, which allows a complex program in one area of the working space of the robot to be replicated in a straight line for any number of duplicate setups. This is done by programming a Pattern Start position and a Pattern End position and then entering the number of iterations to be executed, FIG. 24, step E and entering the Starting Iteration, FIG. 24, step F.

[0112] At FIG. 24, step G, the programmer defines any number of program nodes and essentially copies, pastes, translates that set of program nodes and all necessary robot motions along a defined linear pattern path for the defined number of iterations. The Pattern Workflow subroutine is used for quick and uncomplicated programming of a fixture nest of identical parts, for copying a feature's cut path to various positions on a part, or for intermittent tacking. However, the feature only works successfully when the parts to be cut and the positioning fixture for the assembly have very consistent locations and spacing. When the robot executes the program that should be patterned, it calculates a linear shift from the Pattern Start point to the Pattern End point and adjusts the program accordingly by calculating a shift between the two points divided by the number of iterations, FIG. 24, step H.

[0113] If the work materials are not always in the same position or in a line to use the Pattern Workflow subroutine, at step C, FIG. 19, an operator may use a Search Offset Workflow subroutine which selection allows the operator to manually shift the program in an X, Y, or Z direction by determining and entering required offset values. The relationship between an original part location and an offset part location are shown in screenshot images 515, 520 and 525 in FIGS. 27, 28 and 29, respectively, and the process steps are illustrated in a flowchart presented in FIG. 26.

[0114] At FIG. 26, step A, the operator selects either to Turn Off All Offsets, step B; or selects which Offset to Turn On, step C; or elects to enter an Offset Value to manually activate, step D. The reference feature for each offset is selected at step E. The Turn Off All Offsets turns off all stored program offsets. The Select Offset to Turn On will turn on the offset that is saved for that particular named offset. At step F, the robot either activates the selected offsets or turns off stored offsets in response to the elections made in at the offset choice step, step A. At step G, the path of the collaborative robot during performance of the selected cutting program are offset from this point forward.

[0115] Referring now to step E, FIG. 19, if any of the optional steps B and/or C have been selected, the operator again performs a clearance move of the robot arm 55, the AirMove Workflow defined in step A, FIG. 19 to create a home position. The operator may then select a SearchPartL routine at FIG. 19, step E, the features of which are displayed in screenshot image 530 in FIG. 31. The SearchPart program is used to perform a one-dimensional linear search to identify a program displacement that shifts a program in response to detected positional, rotational or distortional inconsistencies in the work material or unrepeatable part configurations. The SearhPart workflow is shown a flowchart presented in FIG. 30.

[0116] To set up the search, the programmer positions the robot via the hand-guided jogging mode and part, FIG. 30, step A and saves it in the robot program, step B. The programmer then positions the contact point in hand-guided jogging mode in contact with the work materials to be cut, step C and saves it as a start point, step D, which essentially zero's out the search which would return an offset of 0, had the search been executed. At step E, the programmer then selects the offset name for storage and retrieval of the resultant offset value in the robot program and enters a reference feature upon which an offset may be calculated, step F. An exemplary search distance is shown as D in the screenshot in FIG. 31. Optionally, at step G, the operator may override the search distance and generate a new, longer search distance if deemed necessary. The robot is then ready to execute the search and does so by moving in the programmed search direction and waiting for force feedback or a signal from the process unit that the part has been contacted, step H. Thereafter, the robot stops/halts its motion, step I. Once this contact has occurred, the new contact point is compared to the old contact point and the offset value is calculated and stored in the offset name in the robot program, step J. Additionally, the programmer can choose an offset to start with and add to in order to create a compounded two or three-dimensional search.

[0117] Referring again to FIG. 19, depending upon the cut joint configuration required by a given cutting or assembly procedure, at this point in the workflow, an operator has several work paths from which to choose to complete the generation of the cuts specified in the procedure documents. One option designated Cut Template Workflow Custom may be selected at step G, FIG. 19. A Cut Template Workflow flow diagram is shown in FIGS. 32A and 32B. The Cut Template gives the programmer the ability to trace out a cut path having a three-dimensional shape with any number of segments both linear and circular. The Cut Template is used to select and assemble an approach point, a cutting start point, any intermediate cutting points, a cutting end point, and a depart point for a cut, thus ensuring that the robot always move back to a clearance point (approach and depart) to prevent crashing of the system into the work materials.

[0118] A Cut Template is programmed by first choosing to use an automatically positioned approach point or by selecting the waypoint manually. This step is shown at step A in FIG. 32A. If an automatically positioned approach is selected, step B as shown as point A in the Approach screenshot 545 of FIG. 34, in the next step, step C, the operator selects a CutStart waypoint in hand-guided jogging mode shown as point B in the CutStart screenshot 550 of FIG. 34 and programs the CutStart position where the arc will be initiated.

[0119] Next, at FIG. 35, steps F and G, the programmer selects the cut process data and adds in all necessary moves to trace out the cut joint to be cut using any combination of linear and circular CutThru's or CutEnd's. These steps are visually shown in screenshots 560 and 565 in FIGS. 35 and 36, respectively. After all the cut points are set at step H, the programmer chooses an automatic depart position, step I as shown as point D in the Depart screenshot 570 of FIG. 37, or selects a manual depart waypoint in hand-guided jogging mode at step J and programs this waypoint manually at step K. Once all the cut path positions are set, the programmer goes back to the CutStart node at step C, chooses the process to be executed while moving along the path from CutStart to CutThru or CutEnd. This process maybe a straight path or one that has an angle relative to the surface normal to create a bevel edge such as edge 360 in FIG. 12. This process might also be changed at a CutThru in order to update the process based a change in joint geometry. When the robot executes this template, the robot will move to the approach position, step L, set up all cutting monitoring and calculate all necessary angled movement, move to the cut start position, and initiate the arc, step M. Once the arc is established, the robot moves with the necessary movement to the CutThru's or CutEnd point, step N. Once the cut is complete, the robot will move to the depart position and continue with any remaining program moves, step O. A CutEnd point is shown as point C in screenshot 565 in FIG. 36 and a depart point is shown as point D in screenshot 570 in FIG. 37.

[0120] Referring again to the cutting workflow flow chart of FIG. 19, an operator may have a cut procedure to execute that requires shape cutting, step H. A cut template shape is exactly the same as a cut template custom except that the cut is programmed using specific shape inputs instead of positioning each cut point manually. A cut template shape workflow flow diagram is shown in FIGS. 38A and 38B.

[0121] Beginning at step A, a Cut Template Shape is programmed by first choosing to use a shape cut type instead of a custom segmented cut type. The operator then chooses a shape template from a shape library stored in the control program software. The operator then positions all the necessary positions in Step B, and necessary shape dimensions, Step C, to define the desired shape to cut. The operator then creates the necessary shape in Step D.

[0122] Next at step E, the operator chooses to use an automatically positioned approach point of programming or by selecting the waypoint manually, the same manner in which these steps are performed in programming a Cut Template. If an automatically positioned approach is selected, step F, in the next step, step G, the operator selects the process data similar to the Cut Template Custom. He or she selects either an AutoDepart with distance, step J or elects to manually select a depart waypoint, step K. If the manual selection step is chosen, the operator then positions the torch at the depart point manually using the hand-guided jogging mode at step L.

[0123] Once these new parameters are added to the cut, the robot is ready to calculate the physical cut shape and execute the cuts. When the robot executes this template, the robot will move to the approach position, step L, and, at step O, will set up all cutting monitoring, calculates all the individual cut segments along the length of the path. The robot then moves to the cut start position and initiates the arc. Once the arc is established, the robot moves with the necessary movement to the end of the individual stitch cut shown at step P. Once the cut is complete, the robot will move to the depart position and continue with any remaining program moves.

[0124] Referring to FIG. 40, screenshot 580, each shape template will have necessary positions that define the center position of the shape as well as the direction of the shape. The ApproachDepart distances are shown in Approach/DepartMoveL, screenshot 585 as point A, respectively in FIG. 41. FIG. 42, illustrates another CutStart screenshot 590 of a display of cut data such as travel speed, pierce height, pierce delay, cut height, kerf width, and so forth. FIG. 43 is a pictorial representation or screen shot 595 of a Cut Template Shape workflow illustrating a cut depart point and distance CutThru/CutEnd screenshot 600 in FIG. 44 displays through move parameters such as CutApproach, CutStart, ViaPoint, CutThruC, CutEnd and CutDepart as points A through F, respectively for a curved cut path. The CutDepart point D for a curved cut path is shown in the CutThru/CutEnd screenshot 605 in FIG. 45. FIG. 46, screenshot 610 shows through move parameters for a linear cut having at least two segments and having a waypoint at point C. While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claim. Furthermore, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claim and its equivalents.